1990 Ranger 2.9 A4LD to 5 speed manual transmission conversion

[MISWFL]

What parts are needed to do the swap and how hard are they to find? Like what other vehicles would have them. Are the transmissions and T cases married or divorced? Good upgrades to do at the same time? I assume the front axles are the same.

Pedal Assy
Clutch master and slave cylinder
Flywheel and clutch
Transmission, bell housing and shifter
Transfer case?
Drive shaft front and rear?
ECU? ( Smog isn't an issue )
Instrument cluster or swap internal parts
Speedometer cable/sensor

Alternatively, just do the 5 speed swap without running the 4WD stuff for awhile. 5 speed RWD only, until the manual 4WD parts can be found.

I'm contemplating fixing up the truck and driving across the country and I hate automatic transmissions and don't trust them, especially of unknown history. Not for doing anything crazy off road, just for driving in the ice and snow.

Did they ever have a factory 2.3 4WD 5 speed? If so, was there much difference in fuel mileage between the 4 cylinder and 6 cylinder?

 

[RobbieD]

I've done this conversion on a 1990 Bronco II (2.9), but 2WD, so I can comment on some of your items.

Parts for these truck, in general, are getting harder to find. Finding a 2.9 4WD manual '89 to '92 donor truck would be much less of a pain, than trying to piece things one at a time. I found a suitable junkyard donor, and just cut a deal to buy everything that I needed. A 4.0 model would also work.

In your order:

- Pedal assembly should include a clutch switch (OEM name "triple function switch"). The plug for this is in your truck now, with a jumper plug installed.

- You'll also need the fluid reservoir. And, I recommend that you buy the master and slave as a pre-bled set (so much easier).

- Flywheel, clutch; and a pressure plate, throw-out bearing and pilot bearing. Flywheel-to-crank bolts are different between auto and manual, so you'll need the bolts, too.

- Yes; trans, bell housing and shifter. If M5OD, the case is one piece, including the bell housing. The transmission must be from a 2.9 or 4.0 donor.

- Transfer case I don't know.

- Your driveshafts, I don't know. My 2WD B2 is way different from yours. I had a driveshaft made.

- The correct manual ECU I recommend; from what I've read, it will run with an auto ECM, but with a higher idle and a CEL from missing auto trans shift solenoids.

- I kept the same cluster, just installed the PRNDL display block-off plate into it from the donor.
- You will need to decide on what to do with the auto shifter. I used the donor's fixed manual column to rebuild my tilt auto column into a manual version.
- You should get the short transmission harness for the manual, from a donor. You'll need to connect to the reverse light switch, and the right factory harness makes it plug- n-play.

- My auto speedo cable (with the sensor for CC) swapped right in my 2WD. I suspect that yours will, too, just to the transfer case instead.


With the 2.9, the starter is the same for autos and manuals.


There were factory 2.3 4WD 5 speed trucks, but they aren't very common.

I didn't really notice much of an MPG difference before / after on mine, BUT I babied it when it had the weak A4LD, and then after the swap I found hammering the go petal was just too damn tempting. The swap is well worth it.

 

[MISWFL]

I've done this conversion on a 1990 Bronco II (2.9), but 2WD, so I can comment on some of your items.

If M5OD, the case is one piece, including the bell housing. The transmission must be from a 2.9 or 4.0 donor.

There were factory 2.3 4WD 5 speed trucks, but they aren't very common.

I didn't really notice much of an MPG difference before / after on mine, BUT I babied it when it had the weak A4LD, and then after the swap I found hammering the go petal was just too damn tempting. The swap is well worth it.

Thanks!

What kind of fuel mileage do you get with your Bronco?

Is there a choice of 5 speed manual transmissions that fit or only one? I like tall 5th gearing for the freeway. Are the bell housing bolt patterns the same for 4 and 6 cylinder engines?

 

[RobbieD]

I get around 16~17 beating around local. Not any highway driving.

The two choices are the Mazda or Mitsubishi units. The Mazda is considered by most as the better one.

Bell housing bolt patterns are different between the 4 cylinder and 6 cylinders. With the V6 transmissions, the 2.9 and 4.0 have the same bolt pattern, but not the 3.0. The 4.0 has a bigger flywheel and its own starters (two different nose lengths, manual and auto).

On the 2.9 and 4.0 transmissions, the 2.9 transmissions have slightly lower ratios on the lower gears, but I believe that overdrive in both versions have the same ratio.

That's off the top of my head; people more knowledgeable may correct me, or add more info.

 

[MISWFL]

I get around 16~17 beating around local. Not any highway driving.

The two choices are the Mazda or Mitsubishi units. The Mazda is considered by most as the better one.

Bell housing bolt patterns are different between the 4 cylinder and 6 cylinders. With the V6 transmissions, the 2.9 and 4.0 have the same bolt pattern, but not the 3.0. The 4.0 has a bigger flywheel and its own starters (two different nose lengths, manual and auto).

On the 2.9 and 4.0 transmissions, the 2.9 transmissions have slightly lower ratios on the lower gears, but I believe that overdrive in both versions have the same ratio.

Is your Bronco all stock?

Do you know if the 5 speed manual transmissions are the same between 2WD and 4WD?

Are the compatible Mazda and Mitsubishi 5 speed transmissions in those brand mini trucks as well?

What did the 5 speed manual transmission used with the 2.3 fit?

Was a 5 speed manual transmission available with the 2.0 engine?

How about the 5 speed manual transmissions from the 4 cylinder Mustangs, T Birds and Merkur?

 

[RobbieD]

My B2 is all stock. All of my RBVs are 2WD, stock.

2WD / 4WD: No; the cases are different. The 2WD has a tailshaft housing, whereas the 4WD bolts to the Tcase.

I'm not sure. Ford mini trucks before 1983 were Mazda trucks, and Mazda trucks after 1992 are Ford Rangers. I'm not sure of any differences or compatibility between the differently-badged trucks. Mitsu and Mazda designed the transmissions; I'm not sure who actually made them.

Only the 2.3; and I'm not sure without looking at literature, if the 2.0 came with a 5 speed. Seems like I may have had one, so I'm thinking that it did.

Also not sure about transmission compatibility between trucks and passenger cars.

 

[scotts90ranger]

You are stuck with looking for a transmission from a 2.9L or 4.0L Ranger, Bronco II or Explorer (they're out there, I had one with a 5 speed). All 4.0L Rangers and Explorers came with the M5OD transmission where there were like 3 options for the 2.9L even through '92 you could have either a M5OD or Mitsu transmission... I "think" the M5OD is the same length as the A4LD on 4x4 so your drivelines should work. The T case is bolted to the back of the transmission and the speedo cable should be the same between the two so no worry there.

The ECM change is all based on the check engine light for the solenoids as stated above and the higher idle.